TURBO-MATCHING OPTIMIZATION ON COMPRESSOR MAP BY COMPARING DIFFERENT METHODOLOGICAL APPROACH FOR TATA 497 TCIC -BS III ENGINE - AN INVESTIGATION

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1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 9, September 2018, pp Article ID: IJMET_09_09_067 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed TURBO-MATCHING OPTIMIZATION ON COMPRESSOR MAP BY COMPARING DIFFERENT METHODOLOGICAL APPROACH FOR TATA 497 TCIC -BS III ENGINE - AN INVESTIGATION Badal Dev Roy Research Scholar, Department of Mechanical Engineering,SE,VISTAS, Chennai, TN R. Saravanan Dean-Academics and Professor in Mechanical Engineering, Ellenki College of Engg & Tech. Hyderabad, TS M. Chandrasekaran Director & Professor, Department of Mechanical Engineering, SE, VISTAS, Chennai, TN ABSTRACT The Internal Combustion Engine develops more driving force when the compressor obtains required driving force from exhaust gas by means of turbines. The power required by engines completely depend on density of high mass flow and boost pressure of air driven by compressor into intake manifold, hence any mismatch in selecting turbocharger may reduce engine performance drastically than naturally aspirated engine due to inherent response of centrifugal compressor. So turbo matching needs technical skills. Generally design of gas inlet angle and turbine inlet angle are preferred for matching in constant speed engines. Testing methods are mostly preferred for variable speed engines like in Automobile. This research works focuses on investigating and comparing different methodological approach on compressor map for TATA truck engine and suggesting the best approach by varying speed at four levels. Keywords: Compressor map, Surge, Choke Turbocharger, Data- logger method, Sensors, Test Bed, On Road test. Cite this Article: Badal Dev Roy, R. Saravanan and M. Chandrasekaran, Turbo- Matching Optimization on Compressor Map by Comparing Different Methodological Approach for Tata 497 Tcic -Bs Iii Engine - An Investigation, International Journal of Mechanical Engineering and Technology, 9(9), 2018, pp editor@iaeme.com

2 Turbo-Matching Optimization on Compressor Map by Comparing Different Methodological Approach for Tata 497 Tcic -Bs Iii Engine - An Investigation 1. INTRODUCTION Gases emitted from automobile like Carbon Dioxide, CO and Fuel consumption are global issue and improved techniques like downsizing of engine and changes in power train have been developed to curb out such issues [1-4], The turbo-matching is the best alternative to improve vehicle performance by maximizing efficiency and improving fuel economy and reduces the CO, Carbon dioxide emission from diesel engines. The mechanism includes, reducing the charge losses, increasing boost pressure, reducing frictional losses and thereby improving mechanical efficiency, facilitate complete combustion, decreases fuel consumption from ideal to full load condition. Hence this review work highly focuses on the challenges involved in turbocharger-matching at its in vast aspects [4-8]. At low speed of operation, the developed torque of turbo engine is comparatively lower than naturally aspirated engine with comparable power. On the other hand the transient response condition of turbo-charged engine is slow to naturally aspire engine because of transient nature of centrifugal compressor (as compressor needs to reach substantial rotational speeds to produce required boost pressure) [9, 10]. To avoid above inherent difficulties of the turbo charged engine, the perfect match of turbocharger engine is demanded. In recent times VGT technologies, sequentially turbo engines, variable geometrical compressors, [11, 12] or waste gated turbo, double- stage compressor engines [13] are becoming popular to curb such problems. To solve such troubles in Compression Ignition engine downsizing through turbocharger, various technologies have developed such as journal bearing modifications, shaft design improvement, aerodynamics and inertial reduction [14], variable geometry on both sides of turbocharger i.e., compressor and turbine sides [15], double -stage system [16], Positive displacement super-charger operated electrically[17,18], twin turbo system [19], sequentially turbo system [20] and electric compounding of turbocharger [21]. In addition to this alternative system, electronics compressor is used in combination with the turbocharger in certain application [22-24]. A comparison was made by capturing turbo behaviour on City truck drive and city bus drive [26], Knowledge about extraction of real world truck data was captured to check reliability of turbo[27], Further research and development on turbo compressor was carried out to propose a new compressor with higher stability at pressure ratio above 2.5[28]. This article deals with comparison of three different methodology by superimposing engine operating points on compressor map with five different trim sizes to suggest better methodological approach and correct match turbocharger for the TATA 497 TCIC -BS III engine. 2. MATERIALS AND METHODS Presently fleet owners, manufacturers, vendors are marketing turbo with different trim size and capacity. Turbo-matching is a technique for optimizing the capacity and performance of the engine and turbo charger, combining superimposing the operating points on compressor map for better performance [25]. In this article three methodological approaches Simulation, Test Bed and Data-Logger method is employed using five trim sizes of turbocharger compressor is employed for matching the turbo chargers for the TATA 497 TCIC -BS III engine to suggest better approach. The trim is parameter which can be defined as a ratio between the inducer to exducer diameter in the compressor (Ref figure 3) Engine Details The TATA short Haulage Truck engine having Engine specification TATA 497 TCIC -BS III, diesel CI engine, 4 cylinder in-inline water cooled 3.8 litres Engine. Rotary type electronic fuel injection pump is fitted. Power developed is 92 KW, 125 PS, with max. Speed 2400 rpm; rated torque: 400 Nm at 1300 to 1500 rpm and best at 1400 rpm. The bore and stroke of the engine are 97mm and 128 mm respectively editor@iaeme.com

for this investigation, the compressor speed will shoot to a maximum of 200000 rpm. The turbocharger used is waste-gated type. 2.3.

3 Badal Dev Roy, R. Saravanan and M. Chandrasekaran 2.2. Turbochargers specifications Turbo chargers compressor which is specified as B60J67, B60J68, A58N70, A58N72 and A58N75 having compressor trims as 67, 68, 70, 72 and 75 respectively was proposed for this investigation, the compressor speed will shoot to a maximum of rpm. The turbocharger used is waste-gated type Simulation Online simulation package namely Match-Bot is frequently used for the turbo-matching by simulation. In this approach Minimatch V10.5 is used for matching, the engine data like engine speed, Brake Specific Fuel Consumption, displacement, efficiency of compressor, VE of engine, inter-cooler pressure, swept volume and effectiveness, expansion ratio of turbo chargeretc. will be feed through input menu by using pop up menu. Based on the input made by manufacturer which fed in to software, it determine and calculate the engine breathing conditions like required pressure ratio, mass flow rate. Super imposing such data in the compressor map of the turbochargers having higher compressor efficiency and find the better match. Here trims 67,68,70,72 and 75 compressors were used Test Bed The Test bed method is artificial on-road test type.saj Type of test bed is used for testing. This method employed options for selection of vehicle type (light, medium, heavy) etc., and can simulate engine on stable platform by using driving cycle. This method is using dynamometer to vary load as per requirement and collect data s by using sensors fitted on engine and turbo charger. Figure 1 Turbocharger fitted on Test Bed Figure 2 Details of Turbocharger fitted on Test Bed This data obtained are super imposed on compressor map for matching. The Figure 1 depicts the test bed type experimental setup with sensor connected and the turbo charger is highlighted by red circle and Figure 2 depict detailed fitments on Turbocharger On Road Data logger Method Data-logging method is real time on road testing by fitments of sensors on turbocharger and carried on different road conditions and the data s obtained are superimposed on compressor map for engine operating point for matching. Graphtech Type Data-logger is used in this work. The Badal dev roy et al [25] suggested Data logger method in which the performance is evaluating at variable dynamic condition that is real condition. In this method the different trims of turbocharger connected with TATA engine. The Turbocharger is fixed in TATA 1109 truck engine for each trim variants, the breathing operating conditions obtained at various road conditions are taken on an average for comparison with other methods on editor@iaeme.com

Turbo-Matching Optimization on Compressor Map by Comparing Different Methodological Approach for Tata 497 Tcic -Bs Iii Engine - An Investigation compressor map. The combination (i.e. Engine and Turbocharger) is connected with sensors to obtain the breathing condition at various roads.

This method fetches most reliable and reliable match information than other method. Figure 3 Trim of Single stage turbo charger Figure 4 A sample setup of Data-logger Turbo-match Method 3.

4 Turbo-Matching Optimization on Compressor Map by Comparing Different Methodological Approach for Tata 497 Tcic -Bs Iii Engine - An Investigation compressor map. The combination (i.e. Engine and Turbocharger) is connected with sensors to obtain the breathing condition at various roads. The data-logger is a real and actual time field data observing system. The set-up of this method is shown in the Figure 4. This method fetches most reliable and reliable match information than other method. Figure 3 Trim of Single stage turbo charger Figure 4 A sample setup of Data-logger Turbo-match Method 3. EXPERIMENTATION The Test Bed, On-Road Data Logging and Simulation based methods are employed for the five trims sizes namely 67,68,70,72 and 75 were carried out, test bed set up shown in Figure 1 and On Road data-logger turbo matching setup is shown in the figure 4. The figure show sensors and measuring terminals connected with engine on the vehicle with turbocharger (shown with red round mark) Turbo-match performance evaluation The turbocharger matching performance can be perfectly evaluated by proper position of engine breathing condition at a particular engine speed. If breathing condition at a particular engine speed lies on the left of surge line indicates that, flow is instable and cause compressor to stall. The region is called complete in-stable flow region in which the compressor s fluctuates to wider limit. If turbocharger is made to run in this unstable lead to pre-mature failure due to thrust loading on turbo. Surge occurs in two ways. Firstly, if compressor map is too large or it s operating at very low load condition. Secondly, if throttle is closed early after boosting causes turbine to run compressor, but due to close of throttling causes it to move towards surge. If the compressor is small means, it is unable to supply required boost, so breathing condition goes to choke region. In this region the compressor efficiency falls drastically, If the compressor speed is exceeding the allowable limit or our predicted boost beyond the compressor limit means the choke will occur. In this article four speed ranges were used for comparison namely 1000 rpm, 1400 rpm, 1800 rpm and 2400 rpm. The breathing conditions were superimposed on the respective compressor map for comparison of three methodological approach namely Simulation, Test Bed and Data logger (On Road Testing) on TATA 497 TCIC -BS III engine, the compared data obtained through three methods are tabulated trim 67, 70 and 75 in the Table 1 to 2 and trim 68,70 and 72 in the table 3 to editor@iaeme.com

5 Badal Dev Roy, R. Saravanan and M. Chandrasekaran Table 1 Comparison of MFR for Trim Size 67, 70 & 75 by Simulation, Test Bed and On-Road Testing Methods Trim 67 Trim 70 Trim 75 Speed Variant Test On Simulation Bed Road Simulation Test On Bed Road Simulation Test On Bed Road Mass Flow Rate (Kg/Sec.sqrtK/MPa) Table 2 Comparison of PR for Trim Size 67, 70 & 75 by Simulation, Test Bed and On-Road Testing Methods Trim 67 Trim 70 Trim 75 Speed Variant Simulation Test On On On SimulationTest Bed SimulationTest Bed Bed Road Road Road Pressure Ratio Table 3 Comparison of MFR for Trim Size 68, 70 & 72 by Simulation, Test Bed and On-Road Testing Methods Trim 68 Trim 70 Trim 72 Speed Variant Simulation Test On Bed Road Simulation Test On Simulation Test On Bed Road Bed Road Mass Flow Rate (Kg/Sec.sqrtK/MPa) Table 4 Comparison of PR for Trim Size 68, 70 & 72 by Simulation, Test Bed and On-Road Testing Methods Trim 68 Trim 70 Trim 72 Speed Variant Test On Simulation Bed Road Simulation Test On Bed Road Simulation Test Bed On Road Pressure Ratio RESULTS AND DISCUSSION The turbo-match observations were obtained for five turbo-chargers with engine in all three methodologies namely simulation, Test Bed and data-logger method (average of all road condition).the obtained observations were plotted on compressor map for comparison of all three methods. The details of such maps are: the Fig.5 for trim size 67, Fig.6 for trim size 68, Fig. 7 for trim size 70, Fig. 8 for trim size 72 and similarly Fig.9 for trim size editor@iaeme.com

6 Turbo-Matching Optimization on Compressor Map by Comparing Different Methodological Approach for Tata 497 Tcic -Bs Iii Engine - An Investigation Figure5 Comparison of Simulation Test Bed and Road Test for Trim 67 Figure 6 Comparison of Simulation Test Bed and Road Test for Trim editor@iaeme.com

7 Badal Dev Roy, R. Saravanan and M. Chandrasekaran Figure 7 Comparison of Simulation, Test Bed and Road Test for Trim 70 Figure 8 Comparison of Simulation,Test Bed and Road Test for Trim editor@iaeme.com

8 Turbo-Matching Optimization on Compressor Map by Comparing Different Methodological Approach for Tata 497 Tcic -Bs Iii Engine - An Investigation Figure 9 Comparison of Simulation, Test Bed and Road Test for Trim 75 It was observed from compressor maps plots (figure 5 to Figure 9) that the simulation values obtained from Mini match software are slightly higher values than Test Bed and Datalogger values for MFR and Pressure ratio due to assumption made in software during input parameters. As it can be seen that the operating point obtained from Test bed are better than simulation due to slight far away from surge and Choke region of operation and having better compressor performance. Furthermore, when compared Data Logger (On-Road Test) with Simulation and Test bed found that operating points obtained realistic in Road Test are in perfect position far away from surge and choke region of operation and better performance of compressor was observed in terms of Mass Flow rate and pressure ration. Accordingly it was also observed that the all the five trim sizes, at its lower speed from 1000 to 1400 rpm the trim 67 and 68 suffers surge region of operation, and trim 72 and 75 suffers choke region of operation at higher speed ranges from 1800 to 2400 rpm range with poor compressor performance for all the three methods. But when performance of trim 70 was evaluated, found that its operating points is in safe region of operation for all the three methods, i.e, away from surge and choke region of operation and better results was shown with Datalogger(On Road Test) compared to Test Bed and Simulation. It can also be observed from this comparison that the matching performance can be evaluated better at Pressure Ratio above 2.5 and above 1400 rpm but correct optimization between trim size is important in approaching for suggesting perfect turbocharger matching. 5. CONCLUSION The five turbochargers compress or trims namely B60J67, B60J68, A58N70 and A58N72, A58N75 were selected to match with TATA 497 TCIC -BS III engine by three methodological approach and operating points obtained for all trims sizes are plotted for better match using all three methodological approaches. The turbochargers B60J67, B60J68 suffered by huge surge at low engine speed which may cause premature failure of turbocharger and the turbochargers A58N72 and A58N75 experienced the choke at high engine speed and may cause flow reversal and damage blades, but the turbocharger A58N70 ensures safe at all range of speed away from instable region of operation. The simulation, Test Bed and Data-logger (On Road Test) methods were used for investigating the methodological editor@iaeme.com

9 Badal Dev Roy, R. Saravanan and M. Chandrasekaran approach and found that the operating points obtained from Data-Logger (On Road Test) are found having better reliable operating points on compressor map plot having better compressor performance than other methods. Hence the turbocharger A58N70 is suggested for best match for TATA 497 TCIC -BS III engine by using On Road(Data- Logger) Methods. REFERENCES [1] Fontanes., and i, S.,Cantore, G., Mattarelli, E New Concept of Super-charging to High Speed Direct Injection Engines, SAE paper [2] R., Schamel, A., Stokes, J., Lake, T Murphy, R., Osborne,., Turbo-charging for Downsized Direct Injection Engines, SAE paper [3] Schroeer, M.,and Stoffels, H., Aspects of a Down-sized Turbo Gasoline Power-train with DI, SAE paper [4] Guilain, S., and Saulnier, S., CFD Study of Engine Downsizing Using Double StageTurbo- charging, SAE paper [5] Belardini P., Beatrice, C., Bertoli, C., Downsizing of Common Rail Direct Injection Engines: Different Injection Strategies on Combustion, SAE paper [6] Monnier, G., and Lecointe, B., Downsizing a Gasoline Engine Using Turbocharging with Direct Injection, SAE paper [7] Koch, C. R and Atkins, M. J., Wheel Comparison of Several Power-train Technology, SAE paper [8] Gill, D. K., Schwaderlapp, M and Ecker, H. J., Downsizing of Engines: 3Cylinder-4 Cylinder, SAE paper [9] H. C., Konidaris, S., and Attard, W., Comparing the overall Performance of a Downsized Engine in Normally Aspirated, Turbocharged and Supercharged Modes, SAE paper [10] Guilain, S., and Lefebvre, A., Modelling and Measurement of Transient Turbocharged SI Engine, SAE paper [11] C. Guardiola, A., and J. Galindo, H. Climent, Sequentially turbocharged diesel engine on real-life, Int. J. Veh. Des.49 (1/2/3) (2009). [12] J. Domenech., Galindo, H. Climent, Strategies for mode transition in a sequential parallel turbo-charged automotive diesel engine, (2009) [13] Pflüger, Two-stage turbo-chargingimeche, C554/035/98, [14] H., Ikeya, N., Koike, T., Furukaw., Turbo-charger for Improving Acceleration of Passenger Car, SAE paper [15] Kawakami, T., Adachi, K., and Kono, S.,, Development of VFT SAE paper [16] Cho, S., andchoi, C., Development of Specific Fuel Consumption of Passenger Engine with double Stage Turbo-charger, SAE paper [17] Matsuda, N., Kanesaka, H.,Kamata, M., and Ueda, N., New Super-charging System for Heavy Duty Vehicle, SAE paper [18] Heslop, G., Pearce, D., and George, S., Optimum Boost pressure Control for an Electro Super- charging Application, SAE paper [19] Cantemi, C. G., Twin-Turbo Strategical Operation, SAE paper [20] Nakao, M, Fujimoto, Y., and Tashima, Sequential Two stage Turbo-charged Rotary Engine of the Latest RX-7, SAE paper [21] Boeschlin, J. P., Weiss, R., andkattwinkel, T., Mechatronic for Electrical Turbocharger, SAE paper editor@iaeme.com

10 Turbo-Matching Optimization on Compressor Map by Comparing Different Methodological Approach for Tata 497 Tcic -Bs Iii Engine - An Investigation [22] Auffret, N., Tiseira, A., and Arnau, F. J., Analysis of Two-stage Turbo-charging System for US2007 Anti-Pollution Directive for DieselEngines, IJAT, Vol. 9, No. 3, pp (2008). [23] Schag, T. M., Caldwell and D. M., Bonello, The Super- charged Northstar Double Over Head Cam for 4.4L Enginefor Cadillac, SAE paper [24] Brown, J., Torella, E., New, J., Criddle, M., andpallotti, P., Application of Electronic Boosting System for Four-Cylinder S.I. Engine, SAE paper [25] Badal Dev Roy, R. Saravanan, R. Pugazhenthi, M. Chandrasekaran, (2016), Experimental Investigation Of Turbocharger Mapped By Datalogger In I.C. Engine, ARPN Journal of Engineering and Applied Sciences. Vol.11(7), pp [26] O Ryder, D J A Mckenzie, S Johnson, Holset Engineering Co. Limited Huddersfield, UK, Turbo matching Techniques for Truck applications, SAE Paper C602/006/2002. [27] Thomas Grubinger, Nicholas Wickstrom, Knowledge Extraction from Real-World Logged Truck Data, SAE Paper: [ [28] Zhengxinqian., Zhang yangjun.,yang mingyang, Research and development on transonic compressor of high pressure ratio turbocharger for vehicle internal combustion engines, Science China Technological Science, July 2010 Vol.53 No.7: editor@iaeme.com

An Approach for Turbo-matching of B60J67 and A58N75 Turbochargers for a Haulage Truck Engine

An Approach for Turbo-matching of B60J67 and A58N75 Turbochargers for a Haulage Truck Engine Badal Dev Roy #1, Dr. R. Saravanan *2, #1 Research Scholar, Department of Mechanical Engineering, School of